Segmented pyramid roller

ABSTRACT

A roller assembly for processing a substantially planar workpiece includes a first pinch rod and a second pinch rod mounted in opposition to the first pinch rod, the workpiece passing between the first pinch rod and the second pinch rod during operation. A radius rod is also mounted adjacent to the first pinch rod and the second pinch rod, the radius rod being selectively displaceable with respect to the first and second pinch rods to contact the workpiece after the workpiece has passed between the first and second pinch rods, the radius rod conferring a predetermined radius of curvature to the workpiece. The roller assembly further includes a roller mounted onto one of said first pinch rod, the second pinch rod or the radius rod, the roller being selectively positionable along one of the first pinch rod, the second pinch rod and the radius rod.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/418,414, filed on Oct. 15, 2002, and herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

[0002] This invention relates in general to a segmented pyramid roller, and deals more particularly with a segmented pyramid roller which is capable of selectively providing a curved profile, of an adjustable and predetermined radius, to a metal workpiece while maintaining the structural integrity of seams, bends or folds formed thereon.

BACKGROUND OF THE INVENTION

[0003] It is oftentimes desirable that metal workpieces, such as elongated strips of duct or the like, be formed to include a curved section. Roll bending machines are typically employed for this purpose and are commonly manually driven.

[0004] One of the problems sheet metal workers encounter when rolling curved sections of a workpiece having seams or formed edges formed thereon is that the standard pyramid roll bending machines employ rollers which cannot accommodate all the possible seams or forms of the workpiece during the rolling process. As shown in FIG. 1, a standard pyramid roll machine 10 has three forming rollers that work together to provide a radius to a metal workpiece. Two opposed rollers, an upper roller 12 and an unillustrated lower roller, are set to grip the workpiece and drive it through the roll machine 10. The third roll 14 is the radius form roller. It is adjustable and acts to provide a predetermined radius to the workpiece. These three rollers may also be equipped with a clearance channel 16 cut into, for example, the third roller 14 to accommodate those workpieces having bends or folds. Because this clearance channel 16 is cut into the third roller 14, it is fixed in position and does not provide clearance for seams or bends of various widths, or for workpieces with formed edges.

[0005] Moreover, when the workpiece has multiple thicknesses, due to multiple folds or seams along the edges, the rollers of the roll machine 10 must be set to a single dimensional clearance. This may cause the folds or seams to collapse or flatten when rolled. This damages the seam and can make the workpiece unusable.

[0006] With the forgoing problems and concerns in mind, it is the general object of the present invention to provide a segmented pyramid roll machine which overcomes the above-described drawbacks.

SUMMARY OF THE INVENTION

[0007] It is an object of the present invention to provide a segmented pyramid roller.

[0008] It is another object of the present invention to provide a segmented pyramid roller which is capable of selectively providing a curved profile, of an adjustable and predetermined radius, to a metal workpiece while maintaining the structural integrity of seams, bends or folds formed thereon.

[0009] It is another object of the present invention to provide a segmented pyramid roller which is capable of selectively accommodating a workpiece having seams, bends or folds of differing thicknesses.

[0010] These and other objectives of the present invention, and their preferred embodiments, shall become clear by consideration of the specification, claims and drawings taken as a whole.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011]FIG. 1 illustrates a known pyramid roll forming machine.

[0012]FIG. 2 illustrates a segmented pyramid roller, according to one embodiment of the present invention.

[0013]FIG. 3 is a magnified view of the rollers of the segmented pyramid roller shown in FIG. 2.

[0014]FIG. 4 is a partial cross-sectional side view of the segmented pyramid roller shown in FIG. 2.

[0015]FIG. 5 illustrates a partially exploded view of the upper and lower rods and rollers of the pyramid roller shown in FIG. 2

[0016]FIG. 6 illustrates a partially exploded view of the radius rod and rollers of the pyramid roller shown in FIG. 2.

[0017]FIG. 7 is a partial cross-sectional side view of a segmented pyramid roller according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0018]FIG. 2 illustrates a segmented pyramid roller 100, according to one embodiment of the present invention. The segmented pyramid roller 100 includes three full length, one piece guide rods 102, each having a plurality of movable, outer form rollers 104. The one piece, solid rods 102 give the roller 100 the strength to prevent unintended deflection of a workpiece 106 during rolling of the workpiece 106. A guide key 108, shown in FIG. 3, runs along the length of each of the rods 102 and is used to integrally mate with, and provide driven force to, a plurality of tubular shaped rollers 104 which are mounted about the outside diameter of the rods 102. Each of the rollers 104 include a matching key groove 109 for accommodating the guide key 108 therein. Taken together, the rods 102, the guide key 108 and the rollers 104 comprise the forming segmented rollers of the pyramid roller 100.

[0019] The rollers 104 are the forming rollers and are each selectively movable along the length, or longitudinal axis, of the rods 102. The rollers 104 are also movable with respect to one another in order to define differing clearances between separate pairs of the rollers 104, as will be described in more detail later.

[0020] As also shown in FIG. 2, the pyramid roller 100 may be actuated via a handle assembly 105 which is operatively connected to one or more of the rods 102, the force of which being transferred to the non-connected rods 102 via a suitable gear train or the like. Alternatively, the handle assembly 105 may instead be operatively connected directly to a gear train with the motive generated force being transferred to each of the rods 102 in a manner known to one of ordinary skill in the art. Moreover, the present invention equally contemplates that the drive force of the pyramid roller 100 may be any known motor or the like, without departing from the broader aspects of the present invention.

[0021] As shown in FIG. 4, the rods 102 include a lower segmented pinch rod 110 which may be selectively adjusted to capture, or grip, the workpiece 106 between the lower segmented pinch rod 110 and an upper segmented pinch rod 112 via operation of a threaded adjustment assembly 114. Similarly, a radius segmented pinch rod 116 of the roller 100 is likewise displaceable via another threaded adjustment assembly 117 and provides a variable radius of curvature to the workpiece 106.

[0022] That is, as best seen in FIG. 4, as the radius rod 116 is manipulated via the threaded adjustment assembly 117, the radius rod 116 is displaced so as to impart a greater or lesser radius of curvature to the workpiece 106 as the workpiece travels through the roller 100.

[0023] The opposed set of pinch rods, 110 and 112 respectively, can be set to grip the workpiece 106 for drive, while the rollers 104 may each be individually positioned along the rods 102, thereby providing clearance at any place along the length of the rods 102, to accommodate any seams or folds 107 of the workpiece captured therebetween, thereby preventing any deformation of the seams or folds as the workpiece 106 is rolled. That is, the rollers 104 are capable of being positioned so that they may grip the single thickness of the material in places where there are no seams or folds 107, while still accommodating seams or folds in the workpiece 106 which may themselves have differing thicknesses. In operation, the seams or folds 107 pass through the enhanced-clearance areas between the rollers 104 during the rolling process.

[0024] It is therefore an important aspect of the present invention that the present invention permits the selective accommodation of any seams or folds that may be present in the, typically metallic-web, workpiece 106, thereby preserving the integrity of these seams or folds during the forming process. Moreover, by forming each of the rods 102 to include a guide key 108, the present invention also enables the rollers 104 to be positioned at any location along the longitudinal axis of the rods 102 without incurring significant manufacturing delays or requiring specialized tooling.

[0025] It will be readily appreciated that the segmented pyramid roller 100 may be either manually operated or motor driven without departing from the broader aspects of the present invention. Moreover, another threaded adjustment assembly 118, shown in FIG. 2, may be provided to the upper segmented pinch rod 112 to allow the upper pinch rod 112 to be selectively removed from the pyramid roller 100.

[0026]FIGS. 5 and 6 illustrate partially exploded views of the pyramid roller 100. As shown in FIG. 5, the upper and lower rods, 112 and 110 respectively, each include a plurality of rollers 104 spaced along the longitudinal axis of the rods 112 and 110. The third, radius rod 116, shown in FIG. 6, also includes a plurality of rollers 104 spaced along the longitudinal axis of the rods 116. Securing apertures 120 may be formed in the rollers 104 to fix the rollers 104 at specified positions along the rods 110, 112 and 116. The securing apertures 120 permit the introduction of a threaded pin, bolt or the like which hold the rollers 104 in place once the threaded pin or bolt is tightened against the rods 110, 112 and 116.

[0027] As discussed previously in conjunction with FIG. 4, the radius rod 116 is selectively movable to elicit varying radii of curvatures to the workpiece 106 as the workpiece travels through the roller 100. Moreover, as further illustrated in FIG. 6, the threaded adjustment assembly 117 is disposed on either distal end of the radius rod 116, the manipulation of which causes the radius rod 116 to move, at an angle, away from or towards the rods 110 and 112. It will be readily appreciated that only one threaded adjustment assembly 117, with an appropriate gear train, may be alternatively provided without departing from the broader aspects of the present invention.

[0028]FIG. 7 illustrates a partial cross-sectional view of the roller 100, in accordance with another embodiment of the present invention. As shown in FIG. 7, the lower segmented pinch rod 110 may be selectively adjusted to capture, or grip, the workpiece 106 between the lower segmented pinch roller 110 and the upper segmented pinch rod 112 via operation of the threaded adjustment assembly 114. Similarly, the radius rod 116 of the roller 100 is likewise displaceable via another threaded adjustment assembly 117 and provides a variable radius of curvature to the workpiece 106.

[0029] Gearing 122 is also provided so as to transmit the mechanical, or manual, rotation of one of the rods 110, 112 and 116, to the other rods with like speed and force. It will be readily appreciated that any of the rods 110, 112 and 116, may be the driven rod without departing from the broader aspects of the present invention.

[0030] While a roller 100 having rollers 104 on each of the rods 110, 112 and 116 has been disclosed, the present invention is not limited in this regard as alternative configurations are also contemplated by the present invention. In particular, the rollers 104 may be mounted onto either the upper or lower pinch rods, 112 and 110 respectively, without departing from the broader aspects of the present invention. With such an embodiment, the rod which does not support one or more of the rollers 104 would be a smooth rod without the guide key 108 formed thereon. Likewise, the radius rod 116 may also be devoid of any guide key 108 or rollers 104, in accordance with another embodiment of the present invention.

[0031] It will be readily appreciated that even when not all of the rods 110, 112 and 116 are equipped with a guide key 108 and a roller 104, the present invention still provides for conferring a radius of curvature to a workpiece 106 without crushing or otherwise structurally deforming a seam or fold of the workpiece 106, provided that a roller 104 is positioned on one of the rods 110 and 112 such that the seam or fold of the workpiece 106 is positioned to be longitudinally displaced from the roller 104. Another embodiment of the present invention involves utilizing rollers 104 of differing diameters on the rods 110, 112 and 116, thereby selectively changing the clearance between one or more sets of rollers 104 mounted on the rods 110, 112 and 116.

[0032] While the invention has been described with reference to the preferred embodiments, it will be understood by those skilled in the art that various obvious changes may be made, and equivalents may be substituted for elements thereof, without departing from the essential scope of the present invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, but that the invention includes all equivalent embodiments. 

What is claimed is:
 1. A roller assembly for processing a substantially planar workpiece, said roller assembly comprising: a first pinch rod; a second pinch rod mounted in opposition to said first pinch rod, said workpiece passing between said first pinch rod and said second pinch rod; a radius rod mounted adjacent to said first pinch rod and said second pinch rod, said radius rod being selectively displaceable with respect to said first and second pinch rods to contact said workpiece after said workpiece has passed between said first and second pinch rods, said radius rod conferring thereby a predetermined radius of curvature to said workpiece; and a roller mounted onto one of said first pinch rod, said second pinch rod and said radius rod, said roller being selectively positionable along one of said first pinch rod, said second pinch rod and said radius rod.
 2. The roller assembly for processing a substantially planar workpiece according to claim 1, wherein: said roller includes a key groove for accommodating an outwardly extending key guide provided on one of said first pinch rod, said second pinch rod and said radius rod.
 3. The roller assembly for processing a substantially planar workpiece according to claim 2, wherein: said key guide is longitudinally formed on each of said first pinch rod, said second pinch rod and said radius rod.
 4. The roller assembly for processing a substantially planar workpiece according to claim 3, wherein: said roller is mounted onto each of said first pinch rod, said second pinch rod and said radius rod.
 5. The roller assembly for processing a substantially planar workpiece according to claim 1, further comprising: a threaded adjustment assembly operable for selectively displacing said radius rod with respect to said first pinch rod and said second pinch rod.
 6. The roller assembly for processing a substantially planar workpiece according to claim 1, further comprising: a handle assembly for providing drive force to one of said first pinch rod, said second pinch rod and said radius rod.
 7. The roller assembly for processing a substantially planar workpiece according to claim 6, wherein: said handle assembly provides drive force to said first pinch rod, said second pinch rod and said radius rod via a gear train.
 8. The roller assembly for processing a substantially planar workpiece according to claim 2, wherein: said roller includes a radially formed aperture.
 9. The roller assembly for processing a substantially planar workpiece according to claim 8, wherein: said radially formed aperture includes threads inscribed about the inner periphery thereof; and a threaded securing element mating with said inscribed threads for selectively retaining said securing element against one of said first pinch rod, said second pinch rod and said radius rod, thereby securing said roller along one of said first pinch rod, said second pinch rod and said radius rod.
 10. A method for providing a curved profile to a workpiece having a seam, said method comprising the steps of: mounting a first pinch rod in a frame; mounting a second pinch rod in opposition to said first pinch rod, said workpiece passing between said first pinch rod and said second pinch rod; mounting a radius rod adjacent to said first pinch rod and said second pinch rod, said radius rod being selectively displaceable with respect to said first and second pinch rods to contact said workpiece after said workpiece has passed between said first and second pinch rods, said radius rod conferring thereby a predetermined radius of curvature to said workpiece; and releasably securing a roller on one of said first pinch rod, said second pinch rod and said radius rod, said roller being selectively positionable along one of said first pinch rod, said second pinch rod and said radius rod so as not to contact said seam when said workpiece travels through said first pinch rod and said second pinch rod.
 11. The method for providing a curved profile to a workpiece having a seam according to claim 10, further comprising the steps of: forming a key groove longitudinally through said roller; and forming an outwardly extending key guide on one of said first pinch rod, said second pinch rod and said radius rod, said outwardly extending key guide slidably mating with said key groove.
 12. The method for providing a curved profile to a workpiece having a seam according to claim 11, further comprising the steps of: forming said key guide on each of said first pinch rod, said second pinch rod and said radius rod.
 13. The method for providing a curved profile to a workpiece having a seam according to claim 12, further comprising the steps of: mounting said roller onto each of said first pinch rod, said second pinch rod and said radius rod.
 14. The method for providing a curved profile to a workpiece having a seam according to claim 10, further comprising the steps of: utilizing a threaded adjustment assembly to selectively displace said radius rod with respect to said first pinch rod and said second pinch rod.
 15. The method for providing a curved profile to a workpiece having a seam according to claim 10, further comprising the steps of: utilizing a handle assembly to provide a drive force to one of said first pinch rod, said second pinch rod and said radius rod.
 16. The method for providing a curved profile to a workpiece having a seam according to claim 15, further comprising the steps of: utilizing a gear train to transmit said drive force to said first pinch rod, said second pinch rod and said radius rod.
 17. The method for providing a curved profile to a workpiece having a seam according to claim 10, further comprising the steps of: forming a radially extending aperture in said roller.
 18. The method for providing a curved profile to a workpiece having a seam according to claim 17, further comprising the steps of: forming said radially extending aperture to include threads inscribed about the inner periphery thereof; and providing a threaded securing element for selective mating with said inscribed threads for selectively retaining said securing element against one of said first pinch rod, said second pinch rod and said radius rod, thereby securing said roller along one of said first pinch rod, said second pinch rod and said radius rod.
 19. A roller assembly for processing a substantially planar workpiece having a seam, said roller assembly comprising: a frame; a first pinch rod mounted to said frame; a second pinch rod mounted to said frame and oriented in opposition to said first pinch rod, said workpiece passing between said first pinch rod and said second pinch rod; a radius rod mounted adjacent to said first pinch rod and said second pinch rod, said radius rod being selectively displaceable with respect to said first and second pinch rods to contact said workpiece after said workpiece has passed between said first and second pinch rods, said radius rod conferring thereby a predetermined radius of curvature to said workpiece; and a roller mounted onto one of said first pinch rod, said second pinch rod and said radius rod, said roller being selectively positionable along one of said first pinch rod, said second pinch rod and said radius rod so as not to contact said seam when said workpiece travels through said first pinch rod and said second pinch rod. 